Improvement of Long-Term Capacity Planning
Explore how we improved a client’s long-term capacity planning with a model tailored to the unique needs of the client.
GOOD STORIES
When a client sought to ensure a seamless transition from construction to full-scale operations for a new facility, our Improvement team was brought in to develop a comprehensive Operational Readiness Roadmap - outlining key work packages and establishing a clear path for project execution.
THE CHALLENGE
After beginning the construction of a new factory, the client needed support in initiating an operational readiness project to bridge project activities to business requirements in a timely manner. Our Improvement team was brought in to develop a comprehensive operational readiness roadmap, clarify key work packages, and ensure a structured project launch.
The client faced challenges in coordinating multiple stakeholders, defining operational processes, and gathering line of business requirements to ensure readiness and ramp-up of a state-of-the-art API facility and its organization. The goal was to ensure a first-time-right process validation and an efficient transition to everyday operations. Without a structured approach, there was a risk of unassigned tasks and processes falling through the cracks.
OUR APPROACH
To best support the client in their operational readiness project, we started by gaining an understanding of the project scope and an overview of the current state. We did so by conducting Gemba Walks, visiting similar expansion projects and their operational readiness teams in other facilities, and interviewing project leaders to identify key challenges.
Through business process mapping, we outlined key deliverables, identified areas with unclear responsibilities, and assigned ownership to ensure accountability. Based on these insights, we developed a customized business process landscape covering the entire scope of a manufacturing plant. Additionally, we defined the work packages and established the operational readiness organization structure. Finally, we developed a detailed roadmap and created a concept and mock-up of a progress tracking board to monitor implementation.
THE RESULTS
Through Gemba Walks, business process mapping, and stakeholder engagement, we created a clear path forward – identifying areas with unclear responsibilities and gaps while providing a progress-tracking framework to ensure success.
The client received a clear, structured Operational Readiness Roadmap, ensuring a well-organized transition. Additionally, the mock-up of the reporting concept has set the base for real-time progress tracking, enhancing project visibility and decision-making.
KEEN TO LEARN MORE?
At Emendo Improvement, we specialize in building a strong operational foundation to ensure operational readiness.
If you have any questions about our Operational Readiness services, get in touch with Charlotte Hartlev.
HAVE A QUESTION?
An operational readiness roadmap is a structured plan that outlines the steps, responsibilities, and work packages required to transition a project — such as a new facility or system — from construction or implementation to fully operational status. It ensures all processes, teams, and systems are prepared for everyday operation.
Operational readiness helps prevent delays, miscommunications, and costly mistakes by ensuring all business processes, stakeholder responsibilities, and regulatory requirements are defined and in place before operations begin. It supports smooth facility ramp-up and first-time-right validation processes.
Progress tracking boards provide real-time visibility into project milestones, task completion, and potential bottlenecks. They help teams monitor readiness activities, improve accountability, and support data-driven decision-making during the transition from project phase to daily operations.
Yes, operational readiness roadmaps can be adapted for sectors including manufacturing, logistics, healthcare, construction, and IT. Customization ensures the roadmap addresses industry-specific regulations, operational complexities, and organizational structures.
